Mitsubishi Evolution 8 MR 2004 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Lancer Evolution VIII MR Year: 2004 Codes Chassis Code: CT9A 👋 Introduction Market Position Segment: High-performance compact sedan, rally homologation special Competitive Analysis Competitors: Subaru Impreza WRX STI, Ford Focus RS, Honda Civic Type R Key Features Performance Focus: Renowned for its sophisticated all-wheel-drive system, potent turbocharged engine, and exceptional handling characteristics. Rally Heritage: Developed from Mitsubishi's successful World Rally Championship (WRC) program. Manual Value Utility: Essential resource for owners and mechanics aiming to maintain and repair the Evo VIII MR to factory specifications. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service, maintenance, and repair for the 2004 Mitsubishi Lancer Evolution VIII MR Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for full factory service manuals) Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Digital (likely PDF), Printable 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, lubrication system, cooling system, turbocharger system Drivetrain: Manual transmission (6-speed), Active Center Differential (ACD), Super Active Yaw Control (S-AYC), front differential, rear differential, driveshafts, hubs Chassis And Suspension: Front suspension, rear suspension, steering system, braking system (ABS, EBD), wheels and tires Electrical System: Wiring diagrams, battery, charging system, starting system, lighting, instruments and gauges, body electrical, audio system, climate control electronics Body And Interior: Body construction, exterior trim, interior trim, doors, windows, seats, safety equipment (airbags) Procedures Included Maintenance: Scheduled maintenance intervals, fluid changes (oil, coolant, transmission fluid, differential fluids), filter replacements, inspections Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), common fault identification Repair: Step-by-step repair procedures for all major systems, component removal and installation, specifications for torque, clearances, and measurements Adjustments: Alignment procedures, clutch adjustment, throttle cable adjustment Technical Depth Depth: Expert-level detail, suitable for professional technicians and advanced DIY enthusiasts. Includes exploded views, diagrams, and detailed specifications. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Printability: High-resolution, designed for clear printing of text and diagrams Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper: N/A (Digital Format) Searchability Text Search: Likely includes searchable text for quick information retrieval ⚙️ Engine Specifications Primary Engine Engine Code: 4G63T Engine Type: Inline-4, DOHC, 16-valve, turbocharged and intercooled Displacement: 2.0 Liters (1997cc) Performance Horsepower: 271 hp @ 6500 rpm (SAE Net) Torque: 273 lb-ft @ 3500 rpm (SAE Net) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Bosch fuel injectors Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Cooling System Coolant Type: Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent (50/50 mix with distilled water) Oil Specifications Engine Oil Viscosity: SAE 5W-30 Engine Oil Capacity: 4.5 US Quarts (4.2 Liters) with filter change 🔧 Transmission Standard Type: 6-speed Manual Transmission (Type R) Optional Type: N/A (MR models exclusively came with 6-speed manual) Features Drivetrain Control: All-Wheel Drive (AWD) with Active Center Differential (ACD) and Super Active Yaw Control (S-AYC) Fluid Specifications Manual Transmission Fluid: Mitsubishi DiaQueen API GL-4 SAE 75W-80 or equivalent Front Differential Fluid: Mitsubishi DiaQueen LSD Gear Oil SAE 80W-90 or equivalent Rear Differential Fluid: Mitsubishi DiaQueen LSD Gear Oil SAE 80W-90 or equivalent 📐 Dimensions Exterior Length: 176.9 inches (4493 mm) Width: 69.9 inches (1775 mm) Height: 57.3 inches (1455 mm) Wheelbase: 103.3 inches (2624 mm) Weights Curb Weight: 3200 lbs (1451 kg) - approximate Gross Vehicle Weight Rating: Approximately 4000 lbs (1814 kg) 🛡️ Safety Features Ratings NHTSA Front Impact: 4 Stars NHTSA Side Impact: 4 Stars Active Features ABS: Standard Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD) Traction Control: Active Stability Control (ASC) Passive Features Airbags: Driver and front passenger airbags, side curtain airbags (optional/MR specific) Seatbelts: Three-point front and rear seat belts with pretensioners 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, often with premium audio options (e.g., Rockford Fosgate on some trims) Display: Digital clock, odometer, trip meter, basic information display in instrument cluster Driver Assistance ABS Ebd: Standard Anti-lock Braking System (ABS) and Electronic Brake-force Distribution (EBD) Traction Stability: Active Stability Control (ASC) allows for driver intervention to manage traction and stability. Connectivity Auxiliary Input: May have an auxiliary input jack depending on the factory audio system configuration. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or 6 months, whichever comes first (severe duty/performance driving may require more frequent changes) Air Filter Replacement: Every 15,000-30,000 miles or as needed based on inspection Spark Plug Replacement: Approximately 30,000-60,000 miles (refer to manual for specific plug type and gap) Timing Belt Replacement: 60,000 miles or 5 years (critical for 4G63 engine) Fluid Specifications Brake Fluid Type: DOT 3 or DOT 4 (refer to manual for specific recommendation) Power Steering Fluid: Dexron III ATF or Mitsubishi Genuine Power Steering Fluid Known Issues Engine Reliability: Generally robust 4G63 engine, but prone to issues with proper maintenance. Overheating...
Manual transmission (6-speed), Active Center Differential (ACD), Super Active Yaw Control (S-AYC), front differential, rear differential, driveshafts, hubs
Chassis And Suspension:
Front suspension, rear suspension, steering system, braking system (ABS, EBD), wheels and tires
Electrical System:
Wiring diagrams, battery, charging system, starting system, lighting, instruments and gauges, body electrical, audio system, climate control electronics
Expert-level detail, suitable for professional technicians and advanced DIY enthusiasts. Includes exploded views, diagrams, and detailed specifications.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Printability:
High-resolution, designed for clear printing of text and diagrams
Binding Type
Physical Binding:
N/A (Digital Format)
Paper Type
Physical Paper:
N/A (Digital Format)
Searchability
Text Search:
Likely includes searchable text for quick information retrieval
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63T
Engine Type:
Inline-4, DOHC, 16-valve, turbocharged and intercooled
Displacement:
2.0 Liters (1997cc)
Performance
Horsepower:
271 hp @ 6500 rpm (SAE Net)
Torque:
273 lb-ft @ 3500 rpm (SAE Net)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch fuel injectors
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Cooling System
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent (50/50 mix with distilled water)
Oil Specifications
Engine Oil Viscosity:
SAE 5W-30
Engine Oil Capacity:
4.5 US Quarts (4.2 Liters) with filter change
🔧 Transmission
Standard
Type:
6-speed Manual Transmission (Type R)
Optional
Type:
N/A (MR models exclusively came with 6-speed manual)
Features
Drivetrain Control:
All-Wheel Drive (AWD) with Active Center Differential (ACD) and Super Active Yaw Control (S-AYC)
Fluid Specifications
Manual Transmission Fluid:
Mitsubishi DiaQueen API GL-4 SAE 75W-80 or equivalent
Front Differential Fluid:
Mitsubishi DiaQueen LSD Gear Oil SAE 80W-90 or equivalent
Rear Differential Fluid:
Mitsubishi DiaQueen LSD Gear Oil SAE 80W-90 or equivalent
📐 Dimensions
Exterior
Length:
176.9 inches (4493 mm)
Width:
69.9 inches (1775 mm)
Height:
57.3 inches (1455 mm)
Wheelbase:
103.3 inches (2624 mm)
Weights
Curb Weight:
3200 lbs (1451 kg) - approximate
Gross Vehicle Weight Rating:
Approximately 4000 lbs (1814 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4 Stars
NHTSA Side Impact:
4 Stars
Active Features
ABS:
Standard Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD)
Traction Control:
Active Stability Control (ASC)
Passive Features
Airbags:
Driver and front passenger airbags, side curtain airbags (optional/MR specific)
Seatbelts:
Three-point front and rear seat belts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, often with premium audio options (e.g., Rockford Fosgate on some trims)
Display:
Digital clock, odometer, trip meter, basic information display in instrument cluster
Driver Assistance
ABS Ebd:
Standard Anti-lock Braking System (ABS) and Electronic Brake-force Distribution (EBD)
Traction Stability:
Active Stability Control (ASC) allows for driver intervention to manage traction and stability.
Connectivity
Auxiliary Input:
May have an auxiliary input jack depending on the factory audio system configuration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, whichever comes first (severe duty/performance driving may require more frequent changes)
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection
Spark Plug Replacement:
Approximately 30,000-60,000 miles (refer to manual for specific plug type and gap)
Timing Belt Replacement:
60,000 miles or 5 years (critical for 4G63 engine)
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation)
Power Steering Fluid:
Dexron III ATF or Mitsubishi Genuine Power Steering Fluid
Known Issues
Engine Reliability:
Generally robust 4G63 engine, but prone to issues with proper maintenance. Overheating if cooling system is neglected. Clutch wear is common due to performance driving.
Acd S-Ayc System:
Can develop issues with solenoids or sensors; regular fluid changes and diagnostic checks are important.
Turbocharger:
Turbo seals and wastegate actuators can wear over time, especially with aggressive use or poor maintenance.
📚 Vehicle History
Brand Heritage
Motorsport Legacy:
Mitsubishi has a storied history in motorsport, particularly in the World Rally Championship (WRC), where the Lancer Evolution series achieved numerous victories.
Model Evolution
Evolution Series:
The Evolution VIII was the successor to the Evolution VII and represented a significant technological advancement, introducing the ACD and S-AYC systems as standard on the MR variant.
Production
Production Years For Evo Viii:
2003-2005
Mr Variant Distinction:
The 'MR' designation typically signifies Mitsubishi Racing or a premium/performance-oriented variant, often featuring upgrades like a 6-speed gearbox and Bilstein suspension.
🏆 Awards & Recognition
Recognitions
Performance Accolades:
Consistently lauded by automotive journalists and enthusiasts for its exceptional performance, handling, and rally-bred DNA.
Motorsport Titles:
The Lancer Evolution platform is one of the most successful in WRC history, contributing to its desirability and performance reputation.
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